Beruflich Dokumente
Kultur Dokumente
1. Introduction
Depending on the condition of the sugar and
the quantities to be handled, many different methods
are employed for transporting sugar in bulk, including, inter a1ia:-Screw conveyors;
Grasshoppers;
Belt conveyors;
Bucket: elevators.
Most of the above-mentioned types of conveyors
may be seen in almost any sugar factory, and, as
any sugar engineer will be only too quick to explain,
each method has its own peculiar problems which
suit it to certain applications.
Belt conveyors have their attraction for most
applications because of the small number of wearing parts, which results in low maintenance costs;
and the absence of relative movement between the
sugar and conveyor components with which it is in
contact, which results in minimal product degradation. However, they can be extremely difficult to
install succesqfully. In fact, one well-known sugar
engineer who has a number of belt conveyors
handling his final sugar was heard to comment that
"his belt conveyors were fine, they would take away
as much sugar as you can put on them; the snag
is, they bring most of it back again."
It may be stated that almost anyone could successfully design a belt conveyor to carry a given quantity of sugar, or any other commodity. The secret of
the successful design of a conveying system lies
in the design of the transfers to and from the conveyor, to ensure maximum loading of the belt with
minimum spillage.
Where the quantities of sugar to be handled are
low (less than 50 tons per hour) and conveying
distances are comparatively short, other methods of
conveying sugar are frequently found to be more
suitable despite higher maintenance and operating
costs; but once high conveying rates and long distances become necessary, as at the Sugar Terminal,
there would appear to be no alternative to the belt
conveyor, and under these circumstances the control
of spillage becomes of paramount importance. At
the Sugar Terrninal certain of the conveyors are
designed for a duty in excess of 1,000 tons per hour,
at which duty a spillage of only 0.1% will leave
24 tons of sugar per day to be shovelled off the
floor. This is obviously totally unacceptable, and a
thorough knowledge of the behaviour of sugar at a
belt transfer becomes a prerequisite to designing an
acceptable system.
The question may be asked, "What about the
possibility of pneumatic conveying?" The authors
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3. Belt Training
A major practical problem in the operation of belt
conveyors is ensuring that the belt runs reasonably
centrally on the idlers. If the belt runs off too far
it is liable to be damaged by contact with the conveyor structure, while even before this stage is
reached it is possible that excessive spillage may
result from a belt running eccentrically. It is common practice to install training idlers to correct the
tendency of belts to run off. It has been found in
practice that while training idlers may work well
on low-speed belts they do not appear to materially
assist in tracking high-speed belts. Also, where very
flexible belts are installed to run on 45" troughed
idlers the belt tends to ride up over the guide rolls
of the training idlers and this can cause considerable damage to the belt. On high-speed belts it has
been found to be better practice to line up all
idlers and the head and tail pulleys extremely
accurately and to dispense entirely with training
idlers. Any slight tracking problems which may
occur subsequently may be corrected by slight adjustment of the last troughing idler before the head
pulley or the last return idler before the tail pulley.
On slow-speed belts training idlers can perform a
very valuable service, but they cannot be relied upon
to ensure that a belt runs true when intermediate
idlers are not sufficiently accurately set up. It is
essential. therefore, that all conveyor components be
extremely accurately aligned before any conveyor is
con~missioned.
It has been observed at the Sugar Terminal that.
despite the most careful alignment of idlers and head
and tail pulleys, the trackTng characteristics of the
belts vary during the first few weeks of operation.
Thus it is necessary to observe continually a new
belt and occasionally adjust idlers to ~naintainthe
tracking of the belt during the first few weeks of
operation. Once the belt has settled in no further
adjustments are found necessary over a long period
of operation. No training idlers have been fitted on
any of the conveyors in the new section of the Sugar
Terminal. However, side limit switches have been
fitted at the head and tail ends of all belts to trip
the conveyors out in the event of a belt tracking off
seriously.
4. Transfer Chutes
Transfer chutes, as the name implies, are for the
purpose of translerring the conveyed material from
one conveyor belt to the next one in the sequence.
Transfer chutes are the heart of the design of any
conveyor 'installation and the success of the design
of the chutes can make or mar the whole installation.
The object is to transfer all the conveyed material
from one belt to the next with as little loss of height
as possible and without spillage.
Transfer chutes are of two basic types which
operate on entirely different principles. For our
own convenience we have called these (a) feeder
box type, and (b) curtain transfer type.
It has been found in practice that a mixture of
design features of the two types of chute usually
results in unsatisfactory performance.
The feeder box type is probably the best known
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5.1 Scrapers
One of the most effective methods used in
Australia is a steel knife-edged scraper, spring loaded
against stops, just clear of the belt at a little after
3 o'clock on the head pulley. This has a leading-edge
radius of about 1/32" (not more) and is arranged to
fly clear of the belt in the event of build-up taking
place on the head pulley, thus preventing the belt
from being damaged. Such a scraper would plough
off the bulk of the sugar adhering to the belt and
the remainder would be removed by a rotating brush.
The use of such a scraper presupposes a head
drum which is accurately machined if it is to be
effective.
A scraper, currently in use at the Sugar Terminal,
which appears to work tolerably well consists of a
"Linotex" blade in contact with the belt set at a
trailing angle of about 5" at about 6 o'clock to the
head pulley. These scrapers are counterbalanced
by weights and are not backed up by brushes.
Another rubber scraper also in use and which also
appears to work quite well when properly adjusted
is set like the steel-edged scraper mentioned above,
but in contact with the belt, i.e. this scraper has
a leading-edge set tangentially but the whole scraper
assembly is trailing. It is found that under certain
5.2 Brushes
Experiments are currently in progress to establish
the value of this type of cleaning device. Australian
practice is to use a rotating brush with stiff nylon
bristles arranged in tufts on a helix. The brushes are
about 8" diameter and rotate at about 1,000 r.p.m.
The brush should be set so that the bristles lightly
touch the belt. The stickier the sugar the higher
the speed requires to be. The speed in any case
should be such as to make the centrifugal force
more powerful than the stickiness of the sugar, otherwise the brush will clog and become useless in a
short space of time. The effective use of the brush
also p~supposesa true head drum.
The brush should be mounted in the chute so
that all sugar removed from the feeding belt will
fall on to the receiving belt either directly or by
means of the dribble plate.
The brush must be so arranged that it can be
quickly and easily dismantled for cleaning by an
unskilled or semi-skilled person. If this cannot be
achieved the brush will eventually clog and cease
to be effective.
It must be located out of the path of the bulk
of the sugar, and must be preceded by a scraper to
remove bulk sugar carry-over which tends to clog
the brush extremely quickly.
5.3 Water Sprays
Spraying water in small quantities on the belt
just before the loading point makes a big contribution to belt cleanliness with sticky sugar. With dry
sugar the problem is aggravated. Thus in general
it is found advantageous to use water sprays with
low pol sugar and not to use them with high pol.
5.4 Air Jets
Experiments have been carried out using an air
jet to clean the sugar off the belt. Whilst in the short
term it was possible to see a clean strip down the
belt where the jet had been, in the long term no
difference could be noticed. Furthermore, it was
calculated that about 20 h.p. would be required for
each belt and the project was abandoned..
5.5 Slatted Pulley
A device commonly in use by conveyor manufacturers is the slatted beater pulley. This is often
used to increase wrap round a driving pulley or
on either side of a drop tension gear. They do shake
the belt to a degree and in so doing cause some
sugar to fall off the belt. Unfortunately, sugar which
falls off in this way can usually only be reclaimed
by hand and as a cleaning device we do not attach
much importance to them.
6. Protective Devices
Malfunction of conveyors can cause considerable
damage, particularly to the belts, so it is necessary
to consider carefully means for detecting malfunctions so that the conveyors may be stopped before
excessive damage has been caused.
Further, it is a requirement of the Factories Act
that provision be made for emergency stopping of
conveyors from any position adjacent to them. At
the Sugar Terminal all emergency stops are interlocked through a main central control station so that
in the event of any fault on any conveyor, all associated conveyors are also tripped out to prevent
spillage of sugar. The central control console also
includes fault annunciator panels to indicate which
tripping device initiated stopping of any particular
conveyor system to assist in rapidly tracing the cause
of the fault.
The safety devices fitted include, apart from the
normal overload and short circuit trips in the switchgear for each conveyor, the following:(a) Trip wire switches fitted on the operating side
of each conveyor with trip wires running the
full length of the conveyor between head and
tail pulley for emergency manual tripping of
the conveyor.
(b) Side lirnit switches on the belts adjacent to
the head and tail pulleys to trip out the conveyors in the event of a belt tracking off to a
degree which may cause it to rub against the
structure and consequently damage the belt.
(c) Underspeed switches, normally fitted to the
tail pulley of each conveyor to trip the conveyor in the event of a drive losing traction,
which may cause local overheating of the belt
at the drive with consequent serious damage.
(d) Trip switches operated by the overtemperature trip on the fluid coupling in each
conveyor drive.
(e) Silent ratchet back stops fitted to the head
drum of each inclined conveyor to prevent the
conveyor running backwards and depositing
its total load of sugar on the floor at the tail
pulley in the event of failure of the final
chain dlrive.
7. Discussion
In the paper an attempt has been made to cover
most of the broad problems associated with the
design of high-speed belt conveyors for handling
- April 1968
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Proce edings o f The South African Sugar Techrzologists' Association - April I968
88
Proceedings of Tlre South Africcrrl Sugur Teclrr~ologists' as so cia ti or^ - April 1968
89
90
Discussion
- April 1968